Maintenance Manual MM-0194 Single reduction leading axle carrier for tandem axle series MD61. Revised September 2017

Transcription

1 Maintenance Manual MM-0194 Single reduction leading axle carrier for tandem axle series MD61 Revised September 2017

2 Service Notes Before You Begin This publication provides installation and maintenance procedures for the MERITOR Single reduction leading axle carrier for tandem axle series MD61. The information contained in this publication was current at the time of printing and is subject to revision without notice or liability. Access Information on Meritor's Web Site Additional maintenance and service information for Meritor's commercial vehicle systems component lineup is also available at To access information, click on Products, Publications. The screen will display an index of publications by type. You must understand all procedures and instructions before you begin maintenance and service procedures. You must follow your company's maintenance and service guidelines. You must use special tools, when required, to avoid serious personal injury and damage to components. MERITOR uses the following notations to alert the user of possible safety issues and to provide information that will help to prevent damage to equipment and components. WARNING A WARNING indicates a procedure that you must follow exactly to avoid serious personal injury. CAUTION A CAUTION indicates a procedure that you must follow exactly to avoid damaging equipment or components. Serious personal injury can also occur. All rights reserved. No part of this publication may be reproduced in any form or by any means or granted to any third parties without the written permission of MERITOR. MERITOR reserves the right to publish revisions at any time for technical or commercial purposes. Therefore all material contained in this manual is based on the latest information available at time of publication approval. Copyright 2017 by MERITOR NOTE: A note indicates an operational, procedure or instruction that is important for proper service. A NOTE can also supply information that will help to make service quicker and easier. This symbol indicates that you must tighten fasteners to a specific torque. Information contained in this publication was in effect at the time the publication was approved for printing and is subject to change without notice or liability. Meritor Commercial Vehicle Systems reserves the right to revise the information presented to discontinue the production of parts described at any time. 2 MERITOR Leading Axle Carrier MD61

3 Terms used in this manual Manufacturer: MERITOR Manual: Maintenance manual no. MM-0194 Device: Single reduction leading axle carrier Technician: Qualified personnel working on the leading axle carrier maintenance and servicing. Maintenance and servicing: Maintenance and servicing refer to periodical checks and/or replacement of the leading axle carrier parts or components. It also refers to the determining of the cause of a malfunction in order to restore the initial operating conditions. Operator: Any person who will use the leading axle carrier as part of a more complex device. Warranty Warranty applies to the leading axle carrier installed on vehicles for which it was designed. Warranty is void in the following cases: Improper use of the vehicle on which the leading axle carrier is installed (usage conditions, overloading etc.) Tampering with vehicle components that may affect the leading axle carrier performance. Use of non-original spare parts. Improper installation, adjustment, repair or modification. Poor or improper maintenance (including consumables other than those specified). Further information on warranty conditions may be obtained directly from the manufacturer or by referring to the Meritor web site Meritor Leading Axle Carrier MD61 3

4 Contents pg. 05 Section 1 - Introduction 06 Design and Function 11 Routine inspections 12 MN16 without differential IAD (inter axle differential) 13 MN16 without differential IAD - Parts list 14 MD16 with leg cap bridge - Exploded view 15 MD16 with leg cap bridge - Parts list 16 MD16 without leg cap bridge- Exploded view 17 MD16 without leg cap bridge - Parts list 18 Inter axle diff. lock - Exploded view 19 Inter axle diff. lock - Parts list 20 Exploded view 21 Section 2 - Maintenance 22 Removing the carrier for servicing 23 Carrier strip down procedures 35 Carrier rebuild procedures 36 Shim pack calculation 38 Calculating the Preload Spacer 58 Removal and replacement of cross axle diff. lock unit 61 Install the Inter-Axle Differential (IAD) and Lock Shift Assembly 62 IAD Lock Shift Shaft Stop Adjustment 62 Install the Output Bearings ad Thru-Shaft 63 Inspect and Adjust Output Bearing End Play 64 Adjustment of warning light switch 65 Refitting the carrier to axle housing pg. 79 Section 5 - Tightening Torque Values & Lubrication 80 Carrier section & Tightening Torque Table 81 Carrier & Housing assy & Tightening Torque Table 82 Lubrication 83 Section 6 - Troubleshooting 84 Troubleshooting Chart 87 Section 7 - Service Tools 88 MST4400 CT13 Tool - Flange Lock 89 MST4401 CT14 Tool - Seal removal 90 MST4402 CT15 Setting Tool - Pinion 91 MST4403 CT17 Lifting Tool - Pinion 92 MST4404 CT18 Removal Tool - Bearing Cup 93 MST4405 CT19 Removal Tool - Bearing Cup 94 MST4406 CT21 Lifting Tool - Diff. Case 95 MST4407 CT23 Fitting Tool - Bearing Cup 96 MST4408 CT24 Fitting Tool - Bearing Cup 97 MST4409 CT25 Fitting Tool - Bearing Cone 98 MST4410 CT26 Fitting Tool - Pinion Shaft Seal 99 MST4411 CT27 Adjusting Tool - Differential Bearing Adjusters 100 MST4412 Output seal tool 101 MST4807 Inner deflector 102 MST4808 Inner ring 67 Section 3 - Hypoid Gear Contact Patterns 68 Hypoid Gear Pattern Tables 71 Section 4 - Pinion Seal & Output Shaft Replacement 72 Service procedures:forward through-drive carrier Pinion seal replacement 76 Output shaft seal disassembly 77 Output shaft seal assembly 103 Section 8 - Annex Product Notification Letter 107 Section 9 - Appendix 108 Available spacers and combination of calculated spacers 4 Meritor Leading Axle Carrier MD61

5 Introduction 1 pg. 06 Design and Function 11 Routine inspections 12 MN16 without differential IAD (inter axle differential) 13 MN16 without differential IAD - Parts list 14 MD16 with leg cap bridge - Exploded view 15 MD16 with leg cap bridge - Parts list 16 MD16 without leg cap bridge- Exploded view 17 MD16 without leg cap bridge - Parts list 18 Inter axle diff. lock - Exploded view 19 Inter axle diff. lock - Parts list 20 Exploded view Meritor Leading Axle Carrier MD61 5

6 1 Introduction Single Reduction Leading Axle Carrier for Tandem Axle Series Md16-Mn16 Design and Function The input shaft is journalled in two roller bearings. The roller bearings are in the transfer gear housing and the needle bearing in the rear differential side gear of the transfer gear. The shaft has splines for meshing with the transfer gear spider and the differential lock flange. The flange is connected to the input shaft via splines. The transfer housing gear seal is protected against dirt, etc., by means of the dust cover and V-ring on the flange. Fig Meritor Leading Axle Carrier MD61

7 1 Introduction The transfer gear differential consists of a spider with four small differential pinions and two side gears. The four small pinions are journalled on the spider by means of needles (4x41=164) and are held in position by a carrier. The side gears are needle-bearing journalled on the input shaft. The rear side gear is also roller-bearing journalled in the final drive housing. A drive gear is fixed to the front side gear. The rear side gear has internal splines for meshing with the output shaft. The drive gear, on the front side gear, is provided with teeth for the diff. lock. Needle bearing Journals Fig. 1.2 Meritor Leading Axle Carrier MD61 7

8 1 Introduction The main pinion is journalled on two tapered roller bearings. One is in the transfer gear housing and the other in the final drive housing. The intermediate gear is splined to the pinion. The single reduction is of the spiral-bevel type. It is designed for a small reduction with a view to fuel economy. Because of the small reduction, the pinion is large and, for reasons of space, of the spiral-bevel type, which means that the pinion centreline coincides with that of the crown wheel. Transfer gear assembly Fig Meritor Leading Axle Carrier MD61

9 1 Introduction The differential housing is journalled in two tapered roller bearings. The crown wheel is bolted to the differential flange case by means of 10 bolts and is further braced by 10 guide pins. The bolting for the differential case consists of 12 bolts. Needles (4x35=140) are used for journalling the differential pinions on the spider. The output shaft to the rear final drive is journalled in a cylindrical ball bearing in the rear axle casing. The flange for driving the propeller shaft between the final drives is spline-connected to the shaft. On the flange there is a dust cover and in the casing an oil seal. Final drive Fig. 1.4 Meritor Leading Axle Carrier MD61 9

10 1 Introduction In order to ensure reliable and efficient leading axle carrier assembly operation, maintenance intervals, use of lubricants and correct procedures specified by the manufacturer should be strictly observed (refer to Lubrication Maintenance Manual no. 1). For further information contact the manufacturer s engineering department or refer to the Meritor Web site at (see Technical manuals section) WARNING Only original Meritor spare parts should be used. WARNING Use of non-recommended lubricants will adversely affect performance and service life. WARNING Use of non-original parts could seriously affect leading axle carrier assembly performance. 10 Meritor Leading Axle Carrier MD61

11 1 Introduction Routine inspections Service Interval Maintenance operations Delivery Service Check for oil leakage Check bolting Check oil level and top-up if necessary Routine inspections within 6 weeks or at least Check for oil leakage max. 10,000 Km Check bolting every 6 months Check for oil leakage Check rear axle breathers Lubrication See manufacturers lubrication chart Change oil according to lubrication manufacturers chart Meritor Leading Axle Carrier MD61 11

12 Exploded view MN16 without differential IAD (inter axle differential) 12 Meritor Leading Axle Carrier MD61

13 Parts list MN16 without differential IAD (inter axle differential) Ref. Description q.ty 1-2 Gear set (crown wheel/pinion) 1 3 Diff. Carrier 1 4 Diff. bearing cap 1 5 Locating pin 1 6 Cap screw 1 7 Washer cap screw 1 8 Adjusting ring 1 9 Adjusting ring 1 10 Set screw 2 11 Diff. housing left 1 12 Diff. housing right 1 13 Spider 1 14 Diff. pinion 4 15 Spacer plate 4 16 Needle Thrust washer 4 18 Diff. side gear 2 19 Trust washer 6 20 Pin Screw Lock plate 1 23 Hex. socket screw Roller bearing 1 25 Roller bearing 1 26 Pinion bearing 1 27 Shim 28 Spacer sleeve 1 29 Gear helical 1 30 Spacer sleeve 1 31 Pinion bearing 1 Ref. Description q.ty 32 Thrust washer 1 33 Nut 1 34 Gasket 1 35 Cover 1 36 Flange screw 6 37 Roller bearing 1 38 Sleeve 1 39 Thrust washer 1 40 Nut 1 41 Spacer sleeve 1 42 Gear 1 43 Input shaft 1 44 Roller bearing 1 45 Shim 46 Input bearing cage 1 47 Flange screw Seal 1 49 V-ring 1 50 Shield 1 51 Companion flange 1 52 Lock nut 1 53 Plug M12X Gasket 12X Diaphragm 1 56 Cover 1 57 Flange screw 4 58 Identification plate 1 59 Drive screw 4 60 Fixed collar 1 61 Spacer ring 1 62 Circlip 1 Meritor Leading Axle Carrier MD61 13

14 Exploded view MD16 with leg cap bridge 14 Meritor Leading Axle Carrier MD61

15 Parts list MD16 with leg cap bridge Ref. Description q.ty 1 Crown wheel 1 2 Pinion 1 3 Diff. carrier 1 4 Diff. bearing cap 1 5 Locating pin 1 6 Cap screw 1 7 Washer cap screw 1 8 Adjusting ring 1 9 Adjusting ring 1 10 Set screw 2 11 Diff. housing left 1 12 Diff. housing right 1 13 Spider 1 14 Diff. pinion 4 15 Spacer plate 4 16 Needle Thrust washer 4 18 Diff. side gear 2 19 Trust washer 6 20 Pin Screw Lock plate 1 23 Hex. socket screw Roller bearing 1 25 Roller bearing 1 26 Pinion bearing 1 27 Shim 28 Spacer sleeve 1 29 Gear helical 1 30 Spacer sleeve 1 31 Pinion bearing 1 32 Thrust washer 1 33 Nut 1 34 Gasket 1 35 Cover 1 36 Flange screw 6 Ref. Description q.ty 37 Roller bearing 1 38 Diff. side gear 1 39 Needle roller assy 1 40 Spider 1 41 Spacer plate 4 42 Needle Spacer ring 4 44 Diff. pinion 4 45 Thrust washer 4 46 Carrier interaxle diff Gear helical 1 48 Spacer sleeve 1 49 Needle roller assy 1 50 Spacer sleeve 1 51 Engaging sleeve diff. lock 1 52 Input shaft 1 53 Roller bearing 1 54 Shim 55 Input bearing cage 1 56 Flange screw Seal 1 58 Seal, v-ring 1 59 Shield 1 60 Companion flange 1 61 Lock nut 1 62 Spring 1 63 Diaphragm seat 1 64 Fork shift 1 65 Piston 1 66 Diaphragm 1 67 Cover 1 68 Flange screw 4 69 Identification plate 1 70 Drive screw 4 71 Fixed collar 1 72 Spacer ring 1 73 Circlip 1 Meritor Leading Axle Carrier MD61 15

16 Exploded view MN16 without leg cap bridge 16 Meritor Leading Axle Carrier MD61

17 Parts list MN16 without leg cap bridge Ref. Description q.ty 1 Crown wheel 1 2 Pinion 1 3 Diff. carrier 1 4 Diff. bearing cap 1 5 Locating pin 1 6 Cap screw 1 7 Washer cap screw 1 8 Adjusting ring 1 9 Adjusting ring 1 10 Set screw 2 11 Diff. housing left 1 12 Diff. housing right 1 13 Spider 1 14 Diff. pinion 4 15 Spacer plate 4 16 Needle Thrust washer 4 18 Diff. side gear 2 19 Trust washer 6 20 Pin Screw Lock plate 1 23 Hex. socket screw Roller bearing 1 25 Roller bearing 1 26 Pinion bearing 1 27 Shim 28 Spacer sleeve 1 29 Gear helical 1 30 Spacer sleeve 1 31 Pinion bearing 1 32 Thrust washer 1 33 Nut 1 34 Gasket 1 35 Cover 1 36 Flange screw 6 Ref. Description q.ty 37 Roller bearing 1 38 Diff. side gear 1 39 Needle roller assy 1 40 Spider 1 41 Spacer plate 4 42 Needle Spacer ring 4 44 Diff. pinion 4 45 Thrust washer 4 46 Carrier interaxle diff Gear helical 1 48 Spacer sleeve 1 49 Needle roller assy 1 50 Spacer sleeve 1 51 Engaging sleeve diff. lock 1 52 Input shaft 1 53 Roller bearing 1 54 Shim 55 Input bearing cage 1 56 Flange screw Seal 1 58 Seal, v-ring 1 59 Shield 1 60 Companion flange 1 61 Lock nut 1 62 Spring 1 63 Diaphragm seat 1 64 Fork shift 1 65 Piston 1 66 Diaphragm 1 67 Cover 1 68 Flange screw 4 69 Identification plate 1 70 Drive screw 4 71 Fixed collar 1 72 Spacer ring 1 73 Circlip 1 Meritor Leading Axle Carrier MD61 17

18 Exploded view Inter axle diff. lock 18 Meritor Leading Axle Carrier MD61

19 Parts list Inter axle diff. lock Ref. Description q.ty 4 Dog clutch, free 1 5 Pivot pin 1 6 Diff. lock 1 7 Pin 2 9 Clevis pin, 8X Split pin, 2X Selector bar (screw) 1 13 Diaphragm seat 1 14 Spring 1 15 Sleeve 1 16 Diaphragm 1 17 Cover 1 18 Flange screw, M8X Switch plunger 1 20 Lock brace 1 Meritor Leading Axle Carrier MD61 19

20 Exploded view Ref. Description 1 Nut - Companion Flange 2 Companion Flange 3 Output Oil Seal 4 Snap Ring Spacer 5 Output Bearing Cone 6 Output Bearing Cup 7 Output Thru Shaft 8 Axle Housing 20 Meritor Leading Axle Carrier MD61

21 Maintenance 2 pg. 22 Removing the carrier for servicing 23 Carrier strip down procedures 35 Carrier rebuild procedures 36 Shim pack calculation 38 Calculating the Preload Spacer 58 Removal and replacement of cross axle diff. lock unit 61 Install the Inter-Axle Differential (IAD) and Lock Shift Assembly 62 IAD Lock Shift Shaft Stop Adjustment 62 Install the Output Bearings ad Thru-Shaft 63 Inspect and Adjust Output Bearing End Play 64 Adjustment of warning light switch 65 Refitting the carrier to axle housing Meritor Leading Axle Carrier MD61 21

22 2 Maintenance Removing the carrier for servicing Drain the oil from the axle. Jack up the axle and chock front wheels. Release the parking brake. Drain the oil from the hubs. Remove the hub covers. Pull out the sun gear and the axle shaft approximately 160mm taking care not to damage the shaft seals. Lower the vehicle to stand on its wheels, chock wheels and remove the jack. Disengage the differential lock, and remove the cover and diaphragm. Fig. 2.1 Remove the input propeller shaft from the leading axle carrier, and the inter-axle drive shaft to the rear axle at the coupling flanges. Position a suitable lifting device or trolley under the leading axle carrier. Remove the screws fastening the carrier to the axle housing leaving two screws slackened but in position. Use a suitable crowbar in the built-in lever points to extract the leading axle carrier breaking the seal between the leading axle carrier and the axle housing. Ensuring that the leading axle carrier is safely supported on the lifting trolley remove the final two screws and pull the leading axle carrier out of the axle. Fig. 2.2 Fit the leading axle carrier to a rigid overhaul stand. 22 Meritor Leading Axle Carrier MD61

23 2 Maintenance Carrier strip down procedure Remove the pinion nut cover and discard the cover gasket. Block the rotation of the input shaft using a suitable tool fastened to the drive flange. MST CT13 Unscrew, using a torque multiplier, and remove the pinion stem nut. Discard the nut (do not reuse) Remove the tabbed washer under the nut. Disengage the inter-axle differential lock by removing the air line. Fig. 2.3 Fig. 2.5 Open the staking on the pinion stem locking nut. Engage the inter-axle differential lock by applying air pressure. Unscrew the differential lock cover plate bolts and remove the cover plate. Fig. 2.4 Fig. 2.6 Meritor Leading Axle Carrier MD61 23

24 2 Maintenance Slacken the differential lock shaft using a hexagon headed key. (This facilitates subsequent dismantling). Pull off the drive flange - using a standard puller. Fig. 2.7 Fig. 2.9 Unscrew, using a torque multiplier, and remove the input flange nut. Discard the nut - (do not reuse) Unscrew the screws around the input shaft bearing carrier plate. Fig. 2.8 Fig Meritor Leading Axle Carrier MD61

25 2 Maintenance Withdraw the input shaft bearing carrier plate using a puller. Remove the steel shims and retain. Fig Withdraw the input shaft. Remove roller bearing cone from input shaft and cup from input bearing cage. Remove the differential lock collar. Remove the thrust roller bearing. Withdraw and remove the two upper needle roller bearing assemblies and spacer sleeve Slacken the differential lock shaft using a hexagon headed key. (This facilitates subsequent dismantling). Fig Unscrew the differential lock piston, using a hexagon socket. Fig Meritor Leading Axle Carrier MD61 25

26 2 Maintenance Withdraw the piston and spring, take out the diaphragm seat sleeve), and the differential lock fork. Fig Take out the helical spur gear Fig Lift out the differential nest assembly Fig Meritor Leading Axle Carrier MD61

27 2 Maintenance Take out the differential side gear with bearing. Fig Invert the carrier to allow access to the output side of the unit. Using a purpose made drift - push out the bearing cup. This bearing supports the differential side gear. MST CT18 Fig Remove the circlip retaining the cross-axle differential dog clutch, and remove the spacer ring. Fig Meritor Leading Axle Carrier MD61 27

28 2 Maintenance ake the differential lock dog clutch off the differential case splines. Fig Unscrew and remove the two set screws on both sides of the drive unit - discard the screws and use new replacements. Fig Unscrew and remove the four bearing cup screws - discard the screws and replace with new for rebuild. Fig Meritor Leading Axle Carrier MD61

29 2 Maintenance Lift off the bearing cap casting. Remove from right and left side the bearing adjuster rings and bearing cups. Fig Lift out the ring gear and differential case assembly using a bar and sling. WARNING The use of the hoist must be done by experienced trained staff as an incorrect manoeuvre or faulty connection could cause a serious accident. Fig Transfer the ring gear/differential case assembly to bench fixture. Fig Meritor Leading Axle Carrier MD61 29

30 2 Maintenance Unscrew the twelve hexagon socket headed screws on the differential case. mark before disassembling Fig Lift off the differential case half. (tool MST CT21) mark before disassembling Fig Remove and retain the three thrust washers on the side gear. Fig Meritor Leading Axle Carrier MD61

31 2 Maintenance Lift off the cross-axle differential nest (spider and pinion assembly) Fig Remove the opposite differential side gear and three thrust washers Fig Invert the ring gear and prise off the metal locking plate around the ring gear screws. Fig Meritor Leading Axle Carrier MD61 31

32 2 Maintenance Remove the differential casing side bearings using a standard puller. Temporarily mount fixture (MST CT15) on the drive unit casing using the four cap bolts. Invert the carrier to allow access to the input side. Fig Fig Unscrew the ring gear screws to allow replacement of the ring gear. Fit a spacer block or a piece of wood under the helical gear. Fig Fig Meritor Leading Axle Carrier MD61

33 2 Maintenance Use a puller to push the pinion shaft through the bearings. Fig Remove the bearing and spacer. Fig Withdraw the pinion, the bearing assembly and helical spur gear. (MST CT17) Fig Meritor Leading Axle Carrier MD61 33

34 2 Maintenance Drive out pinion bearing cups using a purpose made drift of the correct diameter. (MST CT18) Fig (MST CT19) Fig Meritor Leading Axle Carrier MD61

35 2 Maintenance Carrier Rebuild Procedure Shim pack calculation - Gear Set replacement only (when PC value is marked on the pinion) If the original ring gerar and drive pinion are being installed, refer to Assemble and Install the Drive Pinion Assembly. If a new ring gear and drive pinion are installed, the correct thickness of the shim pack between the inner bearing cup and the carrier must be determined. - Fig Refer to the following procedure. Fig Find the Pinion Cone (H variation) number on the drive pinion you ll replace. Fig. 2.43a and Fig. 2.43b NOTE: The new component could be delivered with a different marking from the one shown in the previous images. Record the number for use later. The PC number can be one of the following values. Refer to calculate Shim Pack Thickness inch (a thousandth of an inch) H + 3 = mm (0.003-inch) H - 3 = mm (0.003-inch) 1 - Outer Bearing Cone 2 - Outer Bearing Cup 3 - Spacer 4 - Shims 5 - Inner Bearing Cone Fig Drive Pinion 7 - Inner Bearing Cup 8 - Spacer 9 - Helical Driven Gear The Pinion Cone variation (H value) indicates the nominal assembly distance. This indication is present for each drive produced before If there is no indication, see next section. Use this number to calculate the thickness of the shim pack between the pinion bearing cage and differential carrier. This variation number is stamped on outer face of the drive gear. 3. If you can t find the H number or it is unreadable, re-install the same shim that you measured in Step 1. In case the shim pack used is not available it is possible to use the average of Manufacturer s Adjusted Shim Pack value which is 0,08 mm for the DT100 carrier. Check tooth contact pattern and adjust the shim pack thickness as necessary to achieve the correct contact pattern. For example H mm or H mm Use the value obtained in Example 2 in Table A to calculate the thickness of the shim pack to install between the bearing cup and the differential carrier. Fig Fig. 2.43a Shims between the differential carrier and inner bearing cup are available in thicknesses of 0.125/0.200/0.500 mm (0.005-/0.008-/0.020-inch). Use this procedure if you ll install a new drive pinion or ring gear set, or if you have to adjust the depth of the original drive pinion. 1. Use a micrometer or a gauge to measure the thickness of the shim pack that you removed from under the inner bearing cup. Record the measurement. - Fig Fig. 2.43b Meritor Leading Axle Carrier MD61 35

36 2 Maintenance 4. Inspect the gear tooth contact pattern. Refer to Inspect the Gear Set Tooth Contact Patterns (Backlash) in this section. 5. Find the H variation on the new drive pinion you ll install. Record the number. Refer to Calculate Shim Pack Thickness in this section. 1 - Part number 2 - Tooth combination number 3 - Pinion Drive Gear pair set number 4 - Variation number Fig. 2.43c 5 - Pinion Drive Gear set manufacturing and testing date, month/year 6 - Pinion Drive Gear set nominal backlash value Calculate Shim Pack Thickness (H value is present on old pinion) 1. If the old Pinion Cone (H) number for a forward tandem carrier is plus (+): Add the H number to the thickness of the old shim pack that you measured in Step 1 2. If the old Pinion Cone (H) number for a forward tandem carrier is minus (-) Subtract the H number from the thickness of the old shim pack that you measured in Step 1 3. If the new Pinion Cone (H) number for a forward tandem carrier is plus (+): Subtract the number from the standard shim pack thickness that you calculated in Step 1 or 2. Use new shims to make a shim pack to the correct thickness. Refer to Table A. 4. If the new Pinion Cone (H) number for a forward tandem carrier is minus (-): Add the number from the standard shim pack thickness that you calculated in Step 1 or 2. Use new shims to make a shim pack to the correct thickness. Refer to Table A. TABLE A Example mm Inches 1. Old Shim Pack Thickness Old H number, H Resulting Value New H Number, H New Shim Pack Thickness Old Shim Pack Thickness Old H number, H Resulting Value New H Number, H New Shim Pack Thickness Old Shim Pack Thickness Old H number, H Resulting Value New H Number, H New Shim Pack Thickness Old Shim Pack Thickness Old H number, H Resulting Value New H Number, H New Shim Pack Thickness Meritor Leading Axle Carrier MD61

37 2 Maintenance Fig Gear Set and Pinion s Bearings Replacement Only A procedure must carried out to determine the Shim thickness to be used for the correct stack height from the centre line of the crown wheel to the inner pinion bearing cup as when we replace pinion s bearings. Dimension B is the shim pack thickness to be determined as formula. Dimension B calculation B = E+ F - H E = Width of the Forward Pinion Bearing Assy F = Value in triangle stamped on Carrier face H = PC value marked on Pinion. All dimension are in mm Fig Meritor Leading Axle Carrier MD61 37

38 2 Maintenance 40, Fig. 2.48a Fig In order to determine the shim thickness, the following formula applies: E: mm Fig F = Carrier distance tolerance stamped on Carrier face: 29/100 = mm Fig. 2.48b H = PC - Value marked on Pinion or drive gear: 5/100 = mm Final Shim Pack Thickness B = E + F - H E = mm F = mm H = mm B= = mm NOTE: If H value is negative add instead to subtract the value (algebraic expressions). Shim kits: 4 thickness available 0.10, 0.15, 0.35 and 0.50 mm Shims Ref Meritor Leading Axle Carrier MD61 Fig. 2.49

39 2 Maintenance NOTE: The kit contains three different dimensions of the spacer. Choose the same dimension present in the original carrier assembly: d (mm) P/N ref. (Pos. 28) Fig Having established the value of shim thickness B, insert shims into the carrier bearing journal. Calculating the Preload Spacer In the DT100 there are 2 different spacers. The first one is present in the position 28. Spacer ref 28: reuse Fig The second spacer is in position 30 (See details in Section 9) The max spacer dimension is the Masterspacer: mm A method to assemble the bearings with the correct preload is to measure the end play of pinion using Masterspacer 23.44mm Tightening the nut to prescribe torque and measured the end play = X mm. Fig Do not scrap the spacer. It is specific for each carrier. NOTE: In case the spacer is damaged use another spacer but with the same dimension. Meritor Leading Axle Carrier MD61 39

40 2 Maintenance Ref. 33: Pinion Nut Nm Masterspacer 23,44 mm From Section 9 it is possible to use the spacer with the same value or, if the exact dimension is not available, it is necessary to use the closest one. The preload is checked turning the pinion through the Pinion Nut (without seal). Requested value without companion flange: 6Nm ± 2Nm. Fig Calculated spacer formula: Calculated spacer = Masterspacer - (x + K) Where: Masterspacer = 23.44mm x = End play measured (e.g. 0.06mm) K = 0.04mm constant value Calculated spacer = Masterspacer - (x + K) = ( ) = 23.34mm Fig For final value see chapter "Rebuilt procedure" section. Ref. final torque check with input shaft and seal. Using a torque wrench on the pinion stem nut, measure the break torque required to rotate the shaft and drive train. The torque should be between 8 20Nm. Spacer ref. 30: 6 different fixed spacer different combinations Spacer ref. 28: reuse 40 Meritor Leading Axle Carrier MD61 Fig. 2.55

41 2 Maintenance WARNING Carefully inspect all parts for damage - cracks - and wear. In case of doubt as to suitability for continued service, discard the part and replace with new. WARNING Meritor recommends that all seals, bearings, and split pins, and certain key fasteners are replaced with new items to ensure reliability in future service. Fig With the carrier in its fixture - output side uppermost - place helical spur gear in position in the carrier casting. NOTE: The gear must be oriented so that the chamfer on the internal splines faces the pinion head. Drive a new pinion bearing cups into position using a purpose made driver of the correct diameter. Drive squarely until fully seated. Drive a new bearing cup into position using a purpose made driver of the correct diameter. Drive squarely until fully seated. Fig Determine the length of the spacer NOTE: See Appendix 2 for details of how to select the length of this spacer which governs the preload on the pinion bearings. Fit new bearing on the pinion stem and press into position. Fit the pinion and spacer in position through the helical gear engaging the splines in the helical gear. Fig Meritor Leading Axle Carrier MD61 41

42 2 Maintenance Fit holding fixture (MST CT15) in place - using the four carrier cap bolts and invert the drive unit to allow access to the input side of the unit. Fig Drive the helical gear down onto the splines of the pinion - using a suitable sleeve. Fit spacer and new bearing. Drive the bearing into its seat using a suitable sleeve or driver. Tool MST CT25 Fig Fig Fig Meritor Leading Axle Carrier MD61

43 2 Maintenance Fit locking washer and lubricate with oil. Fig Fit locking nut using lubricant. Press new bearing onto the differential side gear and place side gear in position. Fig Lubricate teeth thoroughly with grease and bearing cone with axle oil. Fig Meritor Leading Axle Carrier MD61 43

44 2 Maintenance Fit new needle roller bearings in the side gear and lubricate thoroughly with grease. Replace needle bearings in the differential nest pinions, lubricate thoroughly and assemble onto the differential spider. Place differential nest in position on the side gear. Fig Place helical gear in position on the differential nest - with the side gear teeth engaged in the differential nest pinions. Fig Lubricate the inner bore of the gear and fit spacer sleeve followed by two needle roller assemblies. Lubricate and place needle roller thrust bearing in position on the helical gear. Fig Meritor Leading Axle Carrier MD61

45 2 Maintenance Fit spring in the differential lock actuator bore. Fig Place the diaphragm seat collar in position. Lubricate the inter-axle differential lock splined collar engage with differential actuating fork and locate the assembly in position. Apply thread locking compound (Loctite 243) to the threads on the differential lock piston. Fig Fig Fig Meritor Leading Axle Carrier MD61 45

46 2 Maintenance Fit the differential lock piston in position engaging the threads in the differential lock fork and screw the piston using the hexagon socket head to a torque of 200 ± 20Nm. Press new bearing cone onto the input shaft and cup on input bearing cage. Fig Place input shaft and bearings in position engaging the splines in the gear and differential collar. Clean the gasket face of the drive unit - scraping clean of all debris - old sealing compound, etc, to produce a clean smooth mating surface. Apply sealing compound (Dowcorning 7091), in a continuous bead around the gasket face, inside the screw hole positions. Fig Fit two locating dowels in diametrically opposite positions. Fig Fig Meritor Leading Axle Carrier MD61

47 2 Maintenance Locate shims in position on the sealing compound. The thickness of this shim pack determines the end float on the input shaft bearings. See App. 3 for details of how to set the thickness. Fig Fit the bearing housing cover plate in position on the two locating dowels. Fit and cross tighten the cover plate fasteners - tightening to a torque of 85 ± 10 Nm. Fig Fig Meritor Leading Axle Carrier MD61 47

48 2 Maintenance Fit the differential lock diaphragm and cover (note correct orientation) - ensuring firstly that the piston is free and can be depressed slightly by hand. Fig Fit the air adapter elbow connector to the differential lock cover, and cross tighten the cover plate fasteners to a torque of 20 ± 5 Nm. Fig Unscrew the differential lock cover plate bolts and remove the cover plate. Block the rotation of the input flange with a suitable tool fastened to the drive flange, engage the inter-axle differential lock by applying air pressure (at around 6 bar), and tighten the flange retaining nut to a torque of 1200 ± 200 Nm. Tighten the pinion stem retaining nut to a torque of 2000 ± 200 Nm. Fig Meritor Leading Axle Carrier MD61

49 2 Maintenance Fit the input drive flange - ensuring that the rear facing seal is lubricated. Fit the flange retaining nut (do not lubricate). Fig Measure end float on the input shaft by mounting a Dial Test Indicator (DTI) onto the drive unit casting and lifting the drive flange with a lever. The end play movement should be 0.05 ± 0.04 mm. Using a torque wrench on the pinion stem nut, measure the break torque required to rotate the shaft and drive train. The torque should be between 8 to 20 Nm. Standard Tool 75 mm. Stake the retaining nuts on the pinion stem and input shaft using a suitably shaped staking tool to deform the nut flange into the staking indentations in two diametrically opposite positions. Fig The staking deformations should be 3 ± 1 mm deep. Fig Fig Meritor Leading Axle Carrier MD61 49

50 2 Maintenance Fit the pinion stem cover plate and new gasket, and fasten down with 6 cap headed screws tightened to a torque of 20 ± 5 Nm. Fit the ring gear the pin and tighten the screws to a torque of Nm. Fig Place a new locking plate on the ring gear carrier and set in position flat against the differential half casing by using a cylindrical drift to hammer down around the ring gear fixing bolts. Inspect the spider journals and fit new needle bearings in the differential pinions. Lubricate thoroughly. Fig Place the ring gear and differential case in a holding fixture, and assemble three thrust washers and side gear and the differential nest in position, oiling the parts. Fig Fig Meritor Leading Axle Carrier MD61

51 2 Maintenance Place differential spider and pinion assembly in position, oiling the parts. Assemble opposite side gear and three thrust washers in position, oiling the parts. Fig Place second half of the differential case in position. Fasten the two differential housing halves together using 12 socket headed screws tightened to a torque of 200 ± 20 Nm. Fig Fig Fig Meritor Leading Axle Carrier MD61 51

52 2 Maintenance Tighten in cross diameter sequence to a torque of 200 ± 20Nm Lubricate the bearing seats with oil. Fig Locate ring gear and differential assembly in position in the carrier. WARNING The use of the hoist must be done by experienced trained staff as an incorrect manoeuvre or faulty connection could cause a serious accident. Locate new bearing cups on each side. Fig Fig Fig Meritor Leading Axle Carrier MD61

53 2 Maintenance Locate the bearing adjusting rings in their respective threads. Lubricate the outer surfaces of the bearing cups and adjusters with oil. Locate the bearing cap casting in position - ensuring that the adjuster threads in each adjuster are engaged correctly. Fasten the carrier cap casting in place using four bolts cross torqued to 200 ± 20 Nm. Screw up the differential bearing adjusters to preload the bearings prior to measuring gear backlash. (MST CT27) Fig Preload instruction with leg cap bridge Details of preload instructions set gear with 0 backlash; set the 2 adjusting rings against the BRGS and mark the position; turn back and on the two adjusting rings of the same amount and beat with hammer the caps to set the bearing cups. Set a DTI on the carrier casing and locate the sensor on the face of a tooth on the ring gear. Fig Fig Meritor Leading Axle Carrier MD61 53

54 2 Maintenance Rock the ring gear back and forth without disturbing the position of the drive pinion in order to measure gear backlash or free movement. This should be between 0.3 and 0.4 mm Fig Set a DTI on the carrier casing with the indicator probe in contact with the end of the pinion stem. Lever up the crown wheel - and measure the axial movement on the DTI - this should be mm No bearing preload is allowed. Retighten the carrier cap bolts by turning clockwise a further 90 deg ± 5 deg. (i.e. a total of 200 Nm plus 90 deg) Fig Fig Fig Meritor Leading Axle Carrier MD61

55 2 Maintenance Apply thread locking compound to the bearing adjuster set screws, and tighten to a torque of 20 ± 5 Nm Fig Fit differential lock dog clutch spacer and retain with circlip. Fig Meritor Leading Axle Carrier MD61 55

56 2 Maintenance Preload instruction without leg cap bridge Details of preload instructions Method one 1. Place two dial indicators in central and crossways positions onto the outer machined faces of the caps. Fig Adjust Differential Bearings Preload Method two Fit two dial indicators according to the above scheme on X or Y axis against the wing s caps. Fig Use a wrench to tighten bearing adjusting rings until pinion-todrive gear end play and backlash readings are zero. Check that the drive gear is not tight against the pinion. 3. When backlash and end play are zero, continue tightening both adjusting rings until the cap expansion reading is between mm ( inch). This measurement is the sum of readings on both dial gauges. Fig Set the indicators in the zero position. Fig Dial indicator 2 - Bearing Cap 3 - Adjusting Ring Wrench 4 - Adjusting Ring Fig Fig Meritor Leading Axle Carrier MD61

57 2 Maintenance 1. Use the wrench to tighten the adjusting ring bearing opposite of crown side. When one of the DTI moves from zero position. stop the adjusting ring rotation. Mark one of the adjusting ring top notches position as 0. NOTE: while rotating the adjusting ring, thump with a plastic or rubber mallet to set properly the diff bearings. Fig Fig From previous 0 marked position, rotate the adjusting ring among 2 or 3 notches aligning the notches to the lock plate tooth. Fig Meritor Leading Axle Carrier MD61 57

58 2 Maintenance Removal and replacement of cross axle Differential Lock unit Adjustment of differential lock The differential lock mechanism is designed as a preset assembly and adjustment is not possible if problems occur a new differential lock mechanism should be fitted. Fig Remove the split pin in the clevis pin joining the differential lock piston to the differential lock lever. Fig Using an extractor bolt threaded into the pivot pin - withdraw the lever pivot pin to allow removal of the differential lock fork and collar. Fig Meritor Leading Axle Carrier MD61

59 2 Maintenance Split the differential lock actuator. Fig Replace parts if necessary and reassembly. Air-Chamber Fig Apply thread locking compound (Loctite 243) to the screw - and tighten to a torque of 30 ± 5 Nm. Fit the differential lock diaphragm and cover ensuring firstly that the piston is free and can be depressed slightly by hand, Fig Meritor Leading Axle Carrier MD61 59

60 2 Maintenance and cross tighten the cover plate fasteners to a torque of 20 ± 5 Nm. Fig Assemble the differential lock mechanism back into the housing Fig Fit the pivot pin in position. Connect the differential lock lever to the differential lock actuating piston with a clevis pin and split pin. Fig Meritor Leading Axle Carrier MD61

61 2 Maintenance Install the Inter-Axle Differential (IAD) and Lock Shift Assembly 1. If removed, use a hammer and brass drift to install the rear side gear bearing cup. Strike the cup evenly until it is fully seated in the bore. NOTE:if a new rear bearing cone is required, a new matching bearing cup must be installed at the same time. 2. If removed, use a press to install the rear side bearing cone on the rear side gear. 3. Apply lubricant to the IAD spider legs, pinion teeth, side giear teeth, bearing cones, forward and rear side gear journals, and thrust washer surfaces as they are being assembled. Fig To obtain this lubricant, refer to the Service Notes page on the front inside cover of this manual. 4. If removed, install the bearing cup into the input bearing cage. Use a press and a sleeve to install the cup in the cage. The cup is correctly installed when the bottom of the cup is fully seated in the cage bore. 5. Install the two caged needle bearing assemblies into the rear side gear. Install the rear side gear into the carrier. 6. Lubricate with light grease and assemble the needle bearings into the pinions. 7. Install the inter-axle differential spider, pinions and thrust washers into the IAD carrier. Install the IAD assembly into the carrier housing. 8. Install the helical drive gear in its original position using the previously painted marks. 9. Install the helical drive gear spacer, thrust needle bearing and two caged needle bearing assemblies. 10. Insert the IAD lock spring into the IAD opening. 11. Install the IAD clutch collar and shift fork with the fork boss facing outwards. 1. Rear Side Gear Bearing Cup 2. Rear Side Gear Bearing Cone 3. Rear Side Gear 4. Inter-Axle Differential Carrier 5. Differential Pinion Thrust Washer 6. Inter-Axle Differential Pinion 7. Inter-Axle Differential Spider 8. Helical Drive Gear 9. Helical Drive Gear Thrust Washer 10. Input Shaft 11. Needle Bearing Plate 12. Needle Bearings 13. Needle Bearing Retainer Ring 14. Caged Needle Bearing Assembly 15. Spacer Fig Apply sealant to the IAD piston threads. To obtain this sealant, refer to the Service Notes page on the front inside cover of this manual. Install the piston into the shift fork and tighten to Nm ( lb-ft). 14. Place the IAD lock diaphragm and cover in position over the opening. 15. Install the cover capscrews and tighten to Nm (11-18 lb-ft). 12. Insert the diaphragm seat. Meritor Leading Axle Carrier MD61 61

62 2 Maintenance IAD Lock Shift Shaft Stop Adjustment 1. Apply sealant around the circumference of the adjusting screw threads. 2. Install the adjusting screw and jam nut. 3. Loosen the jam nut and adjusting screw until the screw does not touch the end of the shift shaft. Figure Jam Nut and Adjusting Screw 2. Shift Shaft NOTE: If either the bearing cup or the cone need replacement, both parts must be replaced in a fully-matched set from the same manufacturer. 2. If the bearing cones were removed from the thru-shaft, install new bearing cones. Place both cones back-to-back on the thru-shaft. Use a press and a sleeve to install both cones. Apply pressure until the inner cone seats on the shoulder of the thru-shaft. Fig Use a press and a sleeve to install the inner bearing cup in the cage. Place the thru-shaft and bearing assembly in the cage. 4. Use a brass drift, bearing driver tool and a sleeve to install the outer bearing cup into the housing over the thru-shaft. Fig Fig Apply and hold 800 kpa (116 psi) of air pressure to the IAD lock cover valve, so that the shift collar engages the splines on the drive gear. 5. Install the spacer and the snap ring that fastens the outer cup in the cage. The snap ring controls the end play of the output bearing. 6. Inspect and adjust the end play of the thrushaft bearing. Refer to the following procedure. 5. Tighten the adjusting screw until the tip of the screw touches the end of the IAD lock piston. Tighten the screw one additional turn. Tighten the jam nut to Nm (40-55 lb-ft). 6. Check that the clutch collar moves freely and is not clamped to the drive gear. Release the air pressure. Install the Output Bearings and Thru-Shaft 1. Lubricate the bearing cups and the cones with axle lubricant. Fig Press 2. Sleeve 3. Thru-Shaft Fig Output Shaft 2. Bearing Assemblies Fig Snap Ring 4. Output Flange 5. Spacer 1. Sleeve 2. Outer Bearing Cup 3. Outer Bearing Cone 4. Inner Bearing Cup Fig Meritor Leading Axle Carrier MD61

63 2 Maintenance Inspect and Adjust Output Bearing End Play The end play of the output bearing is controlled by the size of the snap ring that holds the bearings in the output cage. The snap rings are available in increments of mm (0.003-inch). Install the snap ring which results in an end play of mm ( inch). 1. Use an installation tool to install the yoke or flange on the thru-shaft. Do not use the nut to draw the yoke onto the shaft. Do not install the oil seal at this time. 2. Install the nut that fastens the yoke or flange to the thrushaft. Place a holding tool on the yoke or flange and tighten the nut to the specified torque. Refer to Section Push the yoke or flange toward the axle housing and rotate the shaft in each direction to verify that the bearings are correctly installed. 4. Install a dial indicator so that the base of the indicator is on the axle housing. The pointer of the indicator must touch the yoke or flange end of the thru-shaft. Adjust the dial indicator to the ZERO setting. Figure Place pry bars under the yoke or flange and push the yoke or flange away from the axle housing. Record the reading on the dial indicator. The reading must be mm ( inch). The reading is the measurement of the end play on the output bearing. 6. If the end play reading is not within the mm ( inch) specification, remove and replace the snap ring that fastens the bearings in the cage. Install a thinner snap ring to increase end play. Install a thicker snap ring to decrease end play. Figure 7. Remove the nut that fastens the yoke or flange to the thrushaft. Use the correct puller tool to remove the yoke. 8. Install the seal using a seal driver and mallet. Refer to Install a Unitized Seal on the Output Shaft in Section Assemble the yoke and nut, then place the holding tool on the yoke or flange. Tighten the nut to specifications. 10. Using a punch or suitable tool, stake the nut on the flange in two places. Output Bearing End Play 1. Snap Ring 1. Flange Fig To increase end play, install a thinner snap ring. To decrease end play, install a thicker snap ring. Fig Meritor Leading Axle Carrier MD61 63

64 2 Maintenance Instructions to install and adjust Differential Lock Sensor Switch Fig Adjustment of the differential warning light switch. Check and adjustment of differential sensor switch is carried out with rear axle installed on vehicle. 1) Check differential lock engagement by blowing in air (6 kg/cm 2 /6 bar approximately) 2) Engage differential lock and tighten sensor switch until the switch point touches the shift fork lever slightly; check that the contact is the one required from the vehicle manufacturer. 3) Starting from the contact, turn the switch of 270 4) Tighten the lock nut to 40 ± 5 Nm 5) Check differential lock engagement several times before running the vehicle on the road. 64 Meritor Leading Axle Carrier MD61

65 2 Maintenance Refitting the Carrier to the Axle Housing Clean the axle housing to carrier mounting face by scraping clear of debris - old sealing compound, etc. Apply a continuous bead of sealing compound (Loctite 5101) to the mounting face. Fit carrier to housing - rotating the drive flange if necessary to engage to output shaft. Fig Take care that the differential lock mechanism is not fouled and remains free to operate when the carrier is fitted. Fasten the carrier to the axle housing with 16 screws tightened in a progressive cross pattern to a torque of Nm. Fit axle shafts in position and sun gears on the ends of the axle shaft splines. Fit end caps on the hubs (see procedure to set the dowel height correctly which governs the half shaft free axial movement or float). Meritor Leading Axle Carrier MD61 65

66 66 Meritor Leading Axle Carrier MD61

67 Hypoid Gear Contact Patterns 3 pg. 68 Hypoid Gear Pattern Tables Meritor Leading Axle Carrier MD61 67

68 3 Hypoid Gear Contact Patterns Tooth contact pattern of the gear set 1. Coast (concave side) 2. Toe 3. Drive (convex side) 4. Heel Coast side Central toward the heel over the face of the gear tooth and in the centre along the tooth profile. 1. Coast 2. Toe Top TOE Good hand-rolled pattern 4. Heel 3. Drive Root Concave HEEL Fig. 3.1 Fig. 3.3 Ideal gear contact pattern Drive side Central toward the toe over the face of the gear tooth and in the centre on the tooth profile. Verification of the gear contact pattern is to be conducted with acceptance criteria as follows: Accepted gear contact pattern at Drive side TOE Good hand-rolled pattern TOE Good hand-rolled pattern CONVEX Heel Fig. 3.2 CONVEX Fig. 3.4 Toe extreme accepted contact pattern 68 Meritor Leading Axle Carrier MD61

69 3 Hypoid Gear Contact Patterns Good hand-rolled pattern CONVEX Heel Fig. 3.5 Heel extreme accepted contact pattern Accepted gear contact pattern at Coast side TOE Good hand-rolled pattern Top Root Concave Fig. 3.6 Toe extreme accepted contact pattern HEEL Good hand-rolled pattern Top Root Concave Fig. 3.7 Heel extreme accepted contact pattern Meritor Leading Axle Carrier MD61 69

70 70 Meritor Leading Axle Carrier MD61

71 Pinion Seal & Output Shaft Replacement 4 pg. 72 Service procedures:forward through-drive carrier Pinion seal replacement 76 Output shaft seal disassembly 77 Output shaft seal assembly Meritor Leading Axle Carrier MD61 71

72 4 Pinion Seal & Output Shaft Replacement The pinion seal replacement detailed below may be carried out with the differential unit installed on the vehicle. Disassembly 1. Unscrew the nuts (1) securing the propeller shaft to the differential companion flange Disconnect the propeller shaft (2) and secure it to the chassis. (Fig. 4.1) Fig With a drilling tool, remove the staking on the pinion lock nut. (fig. 4.2) 4. Block the rotation of the flange (1) using a suitable tool (2). 5. Using a suitable wrench (3), torque multiplier (4) and a suitable service tool slacken the pinion nut. 1 1 Fig Fig. 4.3 Marks 6. If you do not discard the pinion nut and flange, mark the flange position on the pinion and remove it. This may require the use of a standard bearing puller tool. (Fig. 4.4) Fig Meritor Leading Axle Carrier MD61

73 4 Pinion Seal & Output Shaft Replacement 7. Inspect the deflector for damage. If necessary replace the part. (Fig. 4.5) 8. Remove the rotary seal sleeve from the flange. (Fig. 4.5) Assembly 1. If the deflector needs to be replaced, lubricate the flange and use the suitable tool MST4807 for assembly. Deflector Seal Rotary Sleeve Fig. 4.7 Fig Remove seal outer case with use of service tool MST CT14. Discard seal and replace with new for rebuild (Fig. 4.6) 2. If the deflector does not need to be replaced, lubricate the seal rotary sleeve journal of the flange (Fig. 4.7) 3. Fit the seal rotary sleeve on the flange using the suitable tool MST4808. MST CT14 Seal Outer Case Fig Insert seal outer case into service tool MST CT26 (Fig.4.9) Fig. 4.6 Seal Outer Case Fig. 4.9 Meritor Leading Axle Carrier MD61 73

74 4 Pinion Seal & Output Shaft Replacement 5. Press seal into the bore in carrier. When service tool contacts the carrier the seal will be correctly positioned into the bore. (Fig. 4.10) 7. If reused, remove any burrs found on the flage with the aid of a small ball nosed grinding wheel. (Fig. 4.12) 6. Check seal spring has remained in position. (Fig. 4.9) Fig Check seal spring has remained in position. (Fig. 4.11) Fig NOTE: Lubricate the surface of the flange nut and companion flange. Oil the threads. 8. Refit flange and pinion nut. (Fig. 4.13) Fig Fig NOTE: The marks on Pinion and reused flange must now be rotated at 90 avoiding same staking location on nut. Skip note if you use new flange seal nut. 74 Meritor Leading Axle Carrier MD61

75 4 Pinion Seal & Output Shaft Replacement 9. Lock flange with service tool MST CT13 (Fig.4.14) 11. With a suitable ball nosed punch, indent lock nut in two places directly above the slots in the flange. (Figs and 4.17) Fig Tighten flange lock nut to a torque of Nm (Fig. 4.15) Fig Fig Fig Meritor Leading Axle Carrier MD61 75

76 4 Pinion Seal & Output Shaft Replacement Output shaft seal Disassembly Remove the inter-axle drive shaft at the output flange. Block the rotation of the drive flange with a suitable fixture (MST 4400-CT13) Pull off the drive flange using a suitable puller. Fig Fig Unscrew the drive flange retaining nut (note this is double staked and the stakes will be sheared during removal). Discard the nut and always replace with new item. Lever out the drive shaft seal and discard (do not reuse). Tool MST 4401-CT14 Fig Fig Meritor Leading Axle Carrier MD61

77 4 Pinion Seal & Output Shaft Replacement Output shaft seal Assembly 1. If the deflector needs to be replaced, lubricate the flange and use the suitable tool MST4807 for assembly. 5. Replace the seal after thoroughly lubricating with grease and drive into position using a sleeve of the appropriate diameter or a driver tool to ensure that the seal is driven in squarely and correctly seated. (tool MST 4412 ) Fig If the deflector does not need to be replaced, lubricate the seal rotary sleeve journal of the flange (Fig. 4.22) 3. Fit the seal rotary sleeve on the flange using the suitable tool MST4808. Fig Check seal spring has remained in position. (Fig. 4.26) Fig Insert seal outer case into service tool MST CT26 (Fig.4.24) Seal Outer Case Fig Fig Meritor Leading Axle Carrier MD61 77

78 4 Pinion Seal & Output Shaft Replacement 7. If reused, remove any burrs found on the flage with the aid of a small ball nosed grinding wheel. (Fig. 4.27) NOTE: Lubricate the surface of the flange nut and companion flange. Oil the threads. 8. Refit flange and pinion nut. (Fig. 4.28) Fig NOTE: The marks on Pinion and reused flange must now be rotated at 90 avoiding same staking location on nut. Skip note if you use new flange seal nut. Fig Meritor Leading Axle Carrier MD61

79 Tightening Torque Values 5 pg. 80 Carrier section & Tightening Torque Table 81 Carrier & Housing assy & Tightening Torque Table 82 Lubrication Meritor Leading Axle Carrier MD61 79

80 5 Tightening Torque Values Fig Meritor Leading Axle Carrier MD61

81 5 Tightening Torque Values Tightening torque : PN Description Torque (Nm) Degrees Demands 21 Screw - Crown Wheel M16X ), 2) 23 Screw - Differential Housing M16X ), 2) 6 Screw - Differential Bearing Cap M22X2 [torque + angle procedure] ) [torque only] ) 10 Locking Screw Adjusting screw M8X ) 65 Piston - Diff-lock M33x ) 36 Screw - Pinion Cover M8X ) 68 Screw - Diff-lock Cover M8X ) 56 Screw - Cover for input Shaft M12X ) 33 Nut - Pinion M60X ), 3), 8) 61 Nut - Input Shaft/Companion Flange M60X ), 3), 4) Sensor switch * not shown in the section view * NOTE: 1. Threads to be oiled before assembling. 2. Cross-wise tightening = Tightening the fasteners in pairs opposite each other. 3. The axial contact-surface is to be oiled before assembling the nut, PN 33 and After tightening to prescribed torque, the nut, PN 61, must be locked by two opposite deformations of the flange on the nut at the recesses in the companion flange, PN 60. The deformations should be 3 +/-1 mm deep. 5. Change to new screws after 3 reassemblies. 6. For reassembly; use new screws or apply locking fluid. 7. Apply locking fluid, (Loctite 243), before assembly. 8. Nut to be upset in groove. Meritor Leading Axle Carrier MD61 81

82 5 Tightening Torque Values Fig Tightening torque : PN Description Torque (Nm) Demands 3 Flange Screw M16X ), 3) 4 Stud Differential Carrier M16X ), 3) 5 Flange Nut M16X ), 3) 6 Magnetic Plug M ), 3) 7 Plug ) 10 Flange Screw protecting casting ) 21 Output Nut ) NOTE: 1. Cross-wise tightening = Tightening the fasteners in pairs opposite each other. 2. After tightening to prescribed torque, the nut, must be locked by two opposite deformations of the flange on the nut at the recesses in the companion flange. The deformations should be 3 +/-1 mm deep. 3. For reassembly; use new screws or apply locking fluid. Lubrication Oil Specification: Hypoid Gear Oil - S.A.E. J GL5 - tested and approved. Oil Capacity: MN61 = 20 Litres NOTE: For additional information about lubricant please refer to TP0838 and TP Meritor Leading Axle Carrier MD61

83 Troubleshooting 6 pg. 84 Troubleshooting Chart Meritor Leading Axle Carrier MD61 83

84 6 Troubleshooting Shown below is a chart of the most common faults occurring to leading axle carrier. CONDITION Noise, possibly followed by high temperature. POSSIBLE CAUSES Incorrect oil Oil level too low Incorrect backlash Incorrect tooth contact Damaged gears Worn or incorrectly adjusted roller bearings REMEDIES Drain oil and fill up with new in accordance with Specifications Check oil level Adjust Adjust Remove the final drive. Examine gear wheels for damage. Replace damaged parts. Adjust according to instructions. Check and adjust bearings. Replace worn or damaged bearings Thump in leading axle carrier when operating accelerator pedal. First check that the noise is not due to worn universal joints Thrust washers for differential gears worn Differential gears or spider worn Driving wheel loose on hub Worn splines on drive shafts or final drive Replace all thrust washers Replace worn parts Tighten up wheel nuts Replace worn parts Oil leakage Oil level too high Breather valve clogged Sealing rings damaged Incorrectly adjusted or damaged wheel bearings Damaged sealing ring and/or damaged flange Incorrectly adjusted or damaged pinion bearings Diff. lock diaphragm cracked so that compressed air gets into final drive when diff. lock is engaged Check oil level Check breather valve Replace sealing rings Adjust or replace bearings Replace damaged parts Adjust or replace bearings Replace diaphragm 84 Meritor Leading Axle Carrier MD61

85 6 Troubleshooting CONDITION Diff. lock does not engage POSSIBLE CAUSES Leaking air lines Leaking control cylinder Diaphragm cracked Deformed diff. lock control Shift fork guide pin holes staved Electrical fault, switch - solenoid valve Push rod nut incorrectly adjusted REMEDIES Check air lines and unions. 1. Tighten the screws for the upper part of the control cylinder and check for leakage using soapy water 2. Replace diaphragm Replace diaphragm Replace diff. lock control Replace guide pins 1. Check for cable and connection failure 2. Check solenoid valve 3. Check switch Adjust according to instructions Diff. lock does not disengage Faulty solenoid valve Broken return spring Shift fork guide pin holes staved Replace solenoid valve Replace spring Replace guide pins Diff. lock indicator lamp does not light Diff. lock does not engage or engages only partly Electrical fault in lines or connections Bulb blown Incorrectly adjusted indication contact See under Diff. lock does not engage Check lines and connections Replace bulb Replace according to instructions Diff. lock indicator lamp lights continuously Diff. lock does not disengage or disengages only partly Electric cable between indicator lamp and control cylinder has contact with chassis Indicator incorrectly adjusted See under Diff. lock does not disengage Insulate or replace cable Adjust indicator Meritor Leading Axle Carrier MD61 85

86 86 Meritor Leading Axle Carrier MD61

87 Service Tools 7 pg. 88 MST4400 CT13 Tool - Flange Lock 89 MST4401 CT14 Tool - Seal removal 90 MST4402 CT15 Setting Tool - Pinion 91 MST4403 CT17 Lifting Tool - Pinion 92 MST4404 CT18 Removal Tool - Bearing Cup 93 MST4405 CT19 Removal Tool - Bearing Cup 94 MST4406 CT21 Lifting Tool - Diff. Case 95 MST4407 CT23 Fitting Tool - Bearing Cup 96 MST4408 CT24 Fitting Tool - Bearing Cup 97 MST4409 CT25 Fitting Tool - Bearing Cone 98 MST4410 CT26 Fitting Tool - Pinion Shaft Seal 99 MST4411 CT27 Adjusting Tool - Differential Bearing Adjusters 100 MST4412 Output seal tool 101 MST4807 Inner deflector 102 MST4808 Inner ring Meritor Leading Axle Carrier MD61 87

88 7 Service Tools MST4400 CT13 Tool - Flange lock Fig Meritor Leading Axle Carrier MD61

89 7 Service Tools MST4401 CT14 Tool - Seal removal Fig. 7.2 Meritor Leading Axle Carrier MD61 89

90 7 Service Tools MST4402 CT15 Setting Tool - Pinion Fig Meritor Leading Axle Carrier MD61

91 7 Service Tools MST4403 CT17 Lifting Tool - Pinion Fig. 7.4 Meritor Leading Axle Carrier MD61 91

92 7 Service Tools MST4404 CT18 Removal Tool - Bearing Cup Fig Meritor Leading Axle Carrier MD61

93 7 Service Tools MST4405 CT19 Removal Tool - Bearing Cup Fig. 7.6 Meritor Leading Axle Carrier MD61 93

94 7 Service Tools MST4406 CT21 Lifting Tool - Diff.Case Fig Meritor Leading Axle Carrier MD61

95 7 Service Tools MST4407 CT23 Fitting Tool - Bearing Cup Fig. 7.8 Meritor Leading Axle Carrier MD61 95

96 7 Service Tools MST4408 CT24 Fitting Tool - Bearing Cup Fig Meritor Leading Axle Carrier MD61

97 7 Service Tools MST4409 CT25 Fitting Tool - Bearing Cone Fig Meritor Leading Axle Carrier MD61 97

98 7 Service Tools MST4410 CT26 Fitting Tool - Pinion Shaft Seal Fig Meritor Leading Axle Carrier MD61

99 7 Service Tools MST4411 CT27 Adjusting Tool - Diff. Bearing Adjusters Fig Meritor Leading Axle Carrier MD61 99

100 7 Service Tools MST4412 Output seal tool Fig Meritor Leading Axle Carrier MD61

101 7 Service Tools MST4807 Inner deflector Fig Meritor Leading Axle Carrier MD61 101

102 7 Service Tools MST4808 Inner ring Fig Meritor Leading Axle Carrier MD61

103 Annex 1 8 pg. 104 Product Notification Letter Meritor Leading Axle Carrier MD61 103

104 8 Product Notification Letter Introduction Date: First quarter 2013 Subject: MT610 development with separated bearing caps. Product: RS1352HV; RS1370HV; RTH3312; RSH1370, RTH2610B; RT2610HV; RTH3212E; RTH3212D; RT3210HV; RS1365HV; RSH1370E. NOTE: for any information not included in this section please refer to Part 1 of this manual. Forward and rear carriers for MT610 axles will be updated with a new design solution. The current product has a bridge between the two bearing caps, with the planned change this bridge will be removed. Both old and new carriers will be interchangeable. The introduction of this change is driven by product optimization. Old New 104 Meritor Leading Axle Carrier MD61

105 8 Product Notification Letter Old New Parts that will be replaced are as follows : Old p/n Name PCS New p/n Name PCS Carrier Housing DS70 1 A23200W2415 Carrier Housing DS70 1 A23200F2060 Carrier Housing DS65 1 A23200T2412 Carrier Housing DS65 1 A23200C2057 Carrier Housing DT100 1 A23200S2411 Carrier Housing DT100 1 Meritor Leading Axle Carrier MD61 105

106 8 Product Notification Letter Assembly instructions will change as follow. Adjust Axial Play of Differential Bearings Solution one: carriers with leg cap bridges. The axial play of the differential bearings is adjusted to / mm. The play is measured after tightening the bolts to 200 Nm, tighten another 90 +/- 5 degrees. No bearing preload is allowed. Solution two: Carriers without leg cap bridges. Tighten the differential bearing caps screws PN6 min 40Nm. Tighten the crown wheel side bearing adjuster ring while turning the crown wheel by hand. When a resistance is felt at the crown wheel stop tightening the adjuster ring. Back off the adjuster ring till the back lash spec is reached (approx.. 2 segments/notches). Set a DTI gauge at machined surfaces (RL+LU) or (LL+RU) or (LM+RM). Set both DTI gauges to 0. See Figure 1. Move to the opposite side of the crown wheel and tighten the bearing adjusting ring until there is movement on the DTI gauges. NOTE:The bearing cap divergence figure is the combined reading of both DTI gauges. Example: (RL) Gauge 1 = 0.12mm (LU) Gauge 2 = 0.07mm Bearing cap divergence is: 0.12mm mm = 0.19mm. Fig. 8.1 Continue to tighten the bearing adjuster ring until a bearing cap divergence value between 0.05mm and 0.20mm is obtained. Measurements should be taken on (LM+RM) or on both (RU+LL) and (RL+LU) and both have to be inside the tolerance This will ensure the correct bearing pre-load is achieved. Tightening the bolts to 200 Nm, tighten another 90 +/- 5 degrees. Diameters (RU,LL) and (RL,LU) should be max (for DS70) and max Meritor Leading Axle Carrier MD61